1. Meghnaghat Plant: 1 & 2 Attachment Overview Presented by - Sk. Shabbir Hussain. Nausad Ahmed Mridul. Kamrul Hassan. Tasmina Afrin. From: AHSANULLAH UNIVERSITY OF SCIENCE & TECHNOLOGY. 1

2. Contents  Introduction  Organization  Health and Safety  Production Process  Maintenance  Quality control  Supply chain 2

3. Introduction Holcim is one of the leading cement brand in Bangladesh. The name “Holcim” has become synonymous with “quality cement for large construction projects. Holcim’s distribution network covers all seven divisions of Bangladesh. Holcim Bangladesh is the first company to introduce Mobile Concrete Lab in the country.  Holcim has three plants in Bangladesh  Two plants situated in Meghnaghat, Narayanganj and one plant in Mongla. 3

4. Basic Features Two plants and six grinding mills.  Design capacity  Plant 1-Mill-1,2,3 (Capacity-30tph) & Mill 7(Capacity-110tph)  Plant 2-Mill- 4&5 (Capacity-30tph)  Optimized Capacity  Mill-5 32 tph.  Mill-4 34 tph.  Mill-7 140 tph.  Packers  Plant 1- Packer(1,2,5)  Plant 2- Packer 3 4

5. 5 Organization 5 Maintenace Production & process Capex Quality HR Preventive Mechanical Electrical & instrumental Execution Utility Planning Inspection Scheduling Lubrication Head

6. Health and safety Health and safety is the first priority of Lafarge Holcim Ltd. Health and safety programs  Compulsory  Abide by the general health and safety rules  Personal Protective Equipment (PPE) in PPE zone  Specific walkways for pedestrians  Prohibition on using cell phones while walking  Maintaining specified speed limit for driving vehicles inside the plant  Follow various safety signs  Regular health and safety training  Mock drills for training purpose 6

7. Health and Safety management  Elimination > Substitution> Isolation >Control> PPE  Twelve Fatality Prevention Element (FPE)  All the working procedures should be structurally defined & usage of tools should be specified  Ball Mill Hazards:  High noise  Dust  Fall of lifting materials from crane.  Slip,trip and fall  Hit by moving machines  Low head height area 7

8. Health and Safety (Cont.)  Minimum PPE requirements:  Hard hat  Protective glasses  Protective boots with protective toe cap  High visibility clothing (vest)  Ear plugs  Hand gloves 8

9. Production Process 9 Raw Materials Raw material transportation Cement Grinding Process (Ball Mill) Separator Bag Filter Finished product transportation Packer

10. Raw materials Raw materials of cement production  Clinker  Gypsum  Slag  Fly-ash  Limestone Origins of raw materials  Clinker : Thailand, Indonesia & Vietnam  Gypsum : Thailand/Oman  Slag : Japan  Fly-ash : India  Limestone: Oman 10

11. Raw materials unloading Plant- 1  Crane-1 (KSR)- 200 TPH  Crane-2 (E-crane)- 200 TPH  Pneumatic unloader (PFA)- 120 TPH Plant- 2  Mechanical Crane- 1– 100 TPH  Mechanical Crane- 2– 100 TPH  Pneumatic Unloader- 30 TPH 11

12. Material transportation 12 Barge Clinker Slag/ Gypsum PFA Clinker Shed Outside/ Storage PFA Silo Crane Compressor Tubecon Conveyor Belt Truck Vacuum tube Ball Mills Cement Silo Packer Bucket Elevator Raw Material Finished Product Weigh Feeder Belt Crane Bucket Elevator

13. Cement Grinding process 13

14. Cement Grinding Process (Cont.)  Ball mill contains Chromium Ball for grinding process.  Ball mill has two chambers  Chamber 1: Crushing Unit  The balls in this section are of bigger diameter (>50 mm)  Coarser product  Chamber 2: Grinding Unit  Relatively smaller sizes balls are used in this section (12-50 mm)  The output is finer product 14

15. Separator Separators separate fine particles from coarse particles. Main parts:  Two feeder  Air Inlet volute.  Two Assembly  Louvre Assembly(fixed)  Rejecter Cage Assembly (Rotating)  Air & Fines Outlet Volute.  Tails(Rejects Chamber). 15

16. Bag Filter Bag filter is used for separating the air from the fines.  Air suction pulls air and fine mixture inside the bag filter  Bags situated inside the chamber separates air and fine particles  Air escapes from through the bag to the top chamber  Filtered dust free air is sent to the environment  Reverse pulse jet flow clears the bags at pre-programmed intervals.  Dust particles accumulated on bags get detached from bags and fall into hopper via purging process. 16

17. Process Overview 17

18. Packer 18

19. Maintenance 19 Maintenance Team CAPEX & Project team Executive Team PME Preventive maintenance team PME Preventive maintenance team EEE ME

20. Maintenance Management Maintenance Cement (MAC) Block  Twenty Blocks  Level 1 - Ten blocks  Level 2 – Ten blocks 20

21. Maintenance process  Managed by SAP  Corrective maintenance is done only at mill shutdown 21 Planning SchedulingExecution Inspection Weekly Monthly Daily Yearly Improvement Notification Work-order

22. Quality Control  Incoming control  Sample testing  Final raw material testing  Physical Test  Chemical Test 22 Raw Materials Setting time Test Grinding chemical Strength Physical Fineness Component Composition

23. Quality Control (Contd.)  Production Process Control  Hourly Sample Collection  Feed ratio control  Ball mill RPM control  Separator function control 23 Hourly sample collection Mixing all samples Physical test Chemical Test Residue Fineness Setting time Strength Chemical composition

24. Quality Control (Contd.)  Final Control  Packets testing  Packed cement testing  Quality control department also handles issues like  Customer complain,  New product launch,  Performance comparison with competitor brands 24

25. Supply Chain 25 Supply Chain Distribution Inventory Procurement  Purchasing raw materials  Purchasing spare parts  Purchasing new equipment

26. Distribution  Distribution of raw materials 26 Order Placed Mother Vessel Lighter Vessel Plant

27. Distribution(Cont.) o Distribution of packet cement 27 Order Received Finished good inventory Truck load Distributor Customer o Distribution of bulk cement Order Received Cement Silo Bulk Carrier Customer

28. Inventory  Different types of inventory 1.Inventory for raw material 2.Inventory for finished good (Silo) 3.Work in process inventory  Spare Parts Consumable Lubricants Machine Equipment 28

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